Braze bonded nail head lead

Abstract

A braze bonded nail head includes a nail head lead having a first end with first and second sides and a braze alloy preform coupled to the first side of the first end of the nail head lead The braze bonded nail head further includes a weld joint centrally located on the braze alloy preform and extending through the braze alloy preform to the first end of the nail head lead. The weld joint is formed through micro-tig-welding, in alternative embodiments of the invention, one of the nail head lead and the braze alloy preform may include at least one protrusion extending therefrom, while the other of the nail head lead and the braze alloy preforms may include at least one interfit element configured to interfit with the at least one protrusion.

1 . A braze bonded nail head comprising:
 a nail head lead having a first end;   a braze alloy preform coupled to the first end of the nail head lead; and   wherein the nail head lead and the braze alloy preform are permanently coupled together by way of at least one of a weld joint and an interfit joint to form a single use part for assembly brazing.   
     
     
         2 . The braze bonded nail head lead of  claim 1  wherein the weld joint is formed through micro-tig-welding. 
     
     
         3 . The braze bonded nail head lead of  claim 1  wherein the interfit joint is formed by at least one protrusion of one of the nail head lead and the braze alloy preform interfitting with at least one interfit element of the other of the nail head lead and the braze alloy preform. 
     
     
         4 . The braze bonded nail head of  claim 3  wherein the at least one protrusion comprises a center post extending from a first side of the first end of the nail head lead; and
 wherein the at least one interfit element comprises an orifice formed in the center of the braze alloy preform, the orifice configured to interfit with the center post. 
 
     
     
         5 . The braze bonded nail head of  claim 1  wherein a diameter of the first end of the nail head lead is between 0.030 and 0.150 inches. 
     
     
         6 . The braze bonded nail head of  claim 1  wherein a diameter of the braze alloy preform is between 0.030 and 0.150 inches. 
     
     
         7 . The braze bonded nail head lead of  claim 1  wherein a thickness of the braze alloy preform is between 0.0015 to 0.003 inches. 
     
     
         8 . A method of manufacturing a braze bonded nail head lead comprising:
 providing a wire;   forming the wire into a nail head lead, wherein forming the wire into a nail head lead includes forming a first end having a first side and a second side and a shaft extending from the second side of the first end;   aligning the nail head lead with a braze alloy preform;   stamping the braze alloy preform on the first side of the first end of the nail head lead; and   coupling the braze alloy preform to the first side of the first end of the nail head lead by way of a weld joint.   
     
     
         9 . The method of  claim 8  wherein coupling the braze alloy preform to the first side of the first end of the nail head lead by way of a weld joint comprises precision micro-tig-welding the braze alloy preform to the first end of the nail head lead. 
     
     
         10 . The method of  claim 8  further comprising:
 forming at least one protrusion on one of the first end of the nail head lead and the braze alloy preform; 
 forming at least one interfit element on the other of the first end of the nail head lead and the braze alloy preform; 
 wherein the at least one protrusion is configured to interfit with the at least one interfit element. 
 
     
     
         11 . The method of  claim 8  wherein a diameter of the first end of the nail head lead is between 0.030 and 0.150 inches. 
     
     
         12 . The method of  claim 8  wherein a diameter of the braze disc is between 0.030 and 0.150 inches. 
     
     
         13 . The method of  claim 8  wherein a thickness of the braze alloy preform is between 0.0015 to 0.003 inches. 
     
     
         14 . A braze bonded nail head lead comprising:
 a nail head lead having a first end with a first side and a second side and a shaft extending from a second side of the first end;   a braze alloy preform coupled to the first side of the first end of the nail head lead; and   a weld joint centrally located on the braze alloy preform and extending through the braze alloy preform to the first end of the nail head lead.   
     
     
         15 . The braze bonded nail head lead of  claim 14  wherein the weld joint is formed via precision micro-tig-welding. 
     
     
         16 . The braze bonded nail head lead of  claim 14  wherein the nail head lead includes a protrusion extending from the first end of the nail head lead; and
 wherein the braze alloy preform include an interfit element formed therethrough and configured to interfit with the protrusion of the nail head lead. 
 
     
     
         17 . The braze bonded nail head lead of  claim 14  wherein a diameter of the protrusion and a diameter of the interfit element are approximately the same so that the braze alloy preform and the nail head lead are coupled to each other when the protrusion and the interfit element interfit. 
     
     
         18 . The braze bonded nail head of  claim 14  wherein a diameter of the first end of the nail head lead is between 0.030 and 0.150 inches. 
     
     
         19 . The braze bonded nail head of  claim 14  wherein a diameter of the braze alloy preform is between 0.030 and 0.150 inches. 
     
     
         20 . The braze bonded nail head lead of  claim 14  wherein a thickness of the braze alloy preform is between 0.0015 to 0.003 inches.